Experimental studies and mathematical modelling of Inconel 600 with CVD coated TiN/TiCN/Al2O3/ZrCN inserts under dry machining Conditions

Abstract

Inconel 600 is a nickel-based super alloy with applications in the field of Aerospace, Nuclear energy, Heat treatment, and chemical processing industries, and is a difficult to cut material due to its high hot hardness and strength. Coated carbide inserts can improve the machinability of alloys like Inconel 600 and other super alloys. This work is about the machinability characteristics study on Inconel 600 alloy under dry turning environment with high speed machining using CVD coated TiN/TiCN/Al2O3/ZrCN cutting tool insert. Cutting speed (200, 250, and 300 m/min), feed rate (0.05, 0.1, 0.15 mm/rev), and back rake angle (-7, -5, -3°) are considered as machining process parameters. Full factorial design of experiments were performed to evaluate the performance of process parameters on surface roughness and material removal rate. It was found that surface roughness decreased with increase in cutting speed and increases with increase in feed rate. Surface roughness increases with increase in rake angle in negative direction. Material removal rate increases with increase in both cutting speed and the feed rate whereas rake angle had minimal influence. Mathematical modelling was done on the obtained results and found that Rˆ2 value for surface roughness and material removal rate were 99.14% and 98.69% respectively. Analysis of Variance on surface roughness found that feed rate* feed rate is the most influencing parameter with maximum contribution of 34.16% whereas feed rate* cutting speed parameter has maximum influence on material removal rate with contribution of 83.03 %.